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TRANSCRIPT
Century Cement Division Presentation for
19th CII National Energy Award 2018
Unit : Sonar Bangla Cement
TEAM MEMBERSMR. PANKAJ SIL – SR. MANAGERMR. NIKHIL KUMAR - MANAGER 1
TABLE OF CONTENT
SR. NO.
CONTENTS
1 COMPANY PROFILE
2 MAJOR PLANT AND MACHINERY
3 CEMENT MANUFACTURING PROCESS
4 PLANT PERFORMANCE OVER THE YEARS
5 ENERGY EFFICIENCY AND BENCHMARKING
6 LIST OF ENCON TAKEN IN LAST THREE YEARS
7 UTILIZATION OF RENEWABLE ENERGY
8 REDUCTION IN PROCESS WATER CONSUMPTION
2
SR. NO.
CONTENTS
9 CARBON FOOT PRINT REDUCTION
10 DETAILS OF INNOVATIVE PROJECTS
A. 2 PACKER 8 POINT SYSTEM
B. OPTIMIZATION OF BAG FILTER FAN RPM
11 GREEN SUPPLY CHAIN
12 ENCON ORGANIZATION CHART
13 INVOLVEMENT OF EMPLOYEES / TEAM WORK
14 ENERGY MONITORING SYSTEM
15 AWARDS AND ACCOLADES
SONAR BANGLA CEMENT AT A GLANCE
➢ Sonar Bangla Cement , a group of Century Textile & Industry Ltd, is operating a Cement Grinding Unithaving installed capacity of 1.50 MTPA, later up-graded to 2.0 MTPA, situated at Murshidabad District inWest Bengal.
➢ Cement Plant commissioned on 29-03-2013.
➢ A Solar PV Power Plant of 102 KWp capacity commissioned on 21-10-2016.
➢ Presently operating FLS Ball Mills with 2.0 MTPA capacity for Clinker grinding .
➢ Predominantly manufacture Portland Pozzolana Cement (PPC) and catering to the East India Zone as well as northern & central part of India with 45% road dispatch and 55% rail dispatch.
3
MAJOR PLANT AND MACHINERY
WAGON TIPPLERMAKE – ELECON
CAPACITY – 1500 TPH
BALL MILL ,MAKE – FLS
CAPACITY – 150 TPH
CIRCULATING AIR FANFLS
PROCESS BAG FILTERTHERMAX
ROTO PACKERENEXCO
CAPACITY – 240 TPH
WAGON LOADER & TRUCK LOADER
CAPACITY – 120 TPH
H0T AIR GENERATOR MAKE – SINGHANIA AND
WESMAN
SEPERATORMAKE - FLS
4
5
WAGON TIPPLER
CLINKER TANK
GYPSUM YARD
HOPPERS
CEMENT MILL
ROTOPACKER
GYPSUM
FLYASH
CLINKER
6CEMENT SILO
TRUCK LOADING
WAGON LOADING
FLY ASH BULKER
DRY FLY ASH SILO
PLANT PERFORMANCE OVER THE YEAR
7
Unit’s Performance
14.5
15
15.5
16
16.5
17
17.5
14-15 15-16 16-17 17-18
Cement Production (LMT)
Cement Production (LMT)
16.52
17.26
16.95
15.53
30
31
32
33
34
35
14-15 15-16 16-17 17-18 Target
34.33
32.08
33.58
34.82 35
Fly Ash Addition %
In Q-1 : FY 2018-19 Fly Ash Addition is 35 %
8
Electrical Energy Performance
0
10
20
30
40
14-15 15-16 16-17 17-18
Specific Power Consumption (KWh/Ton) of Cement Grinding
Specific Power Consumption (KWh/Ton) of CementGrinding
38.99
32.29 30.47 29.30
0
0.5
1
1.5
2
2.5
3
3.5
14-15 15-16 16-17 17-18
Specific Power Consumption (KWh/Ton) of Cement Despatch
Specific Power Consumption (KWh/Ton) of CementDespatch
3.293.05 2.81
2.41
9
Electrical Energy Performance
0
10
20
30
40
50
14-15 15-16 16-17 17-18
Total Specific Power Consumption (KWh/Ton) of Cement
Total Specific Power Consumption (KWh/Ton) of Cement
45.61
37.22 35.25 33.60
10
OUR PRESENCE IN BENCHMARK
35.25 33.6
2528
0
10
20
30
40
KW
H/T
ON
BENCHMARKS
FY-16 FY-17 INTERNATIONAL BENCHMARK NATIONAL BENCHMARK
11National Benchmark :- CII and CMA Energy Benchmarking for Cement Industry Manual May2015International Benchmark :- http://ietd.iipnetwork.org/content/cement#benchmarks
LIST OF ENCON TAKEN IN LAST THREE YEARS
12
Energy Saving Projects implemented in FY 2015-16 with No Investment
S. No Energy Saving projectAnnual Savings
(Rs. In Lakh)
Investment Required
( Rs. In Lakhs)
Payback Period
( In Months)
1 Avoid Damper Loss in CM-2 Circulating Fan & Mill Vent Fan 17.08 Nil Immediate
2 Avoid Damper Loss in CM-1 Circulating Fan & Mill Vent Fan
11.17 Nil Immediate
3 Avoid compressed air leakage in the plant 13.00 Nil Immediate
4 Reduced the compressed air generating pressure for feed building compressor
3.50 Nil Immediate
5 Reduced the compressed air generating pressure for Cement Mill compressor
3.00 Nil Immediate
6 Reduce the voltage of Load Centre No-1 Transformer -2 2.68 Nil Immediate
7 Optimize the capacity of Identified Motor 2.50 Nil Immediate
8 Optimize Lighting Voltage in Plant 2.30 Nil Immediate
13
Energy Saving Projects implemented in FY 2015-16 With Investment
S. No Energy Saving projectAnnual Savings
(Rs. In Lakh)
Investment Required
( Rs. In Lakhs)
Payback Period
( In Months)
9 Improve the power factor of the system 7.47 15 24
10 Optimize the operation of Packer 1 Bag Filter 14.80 13 10
12 Optimize the operation of Packer 2 Bag Filter 12 12 12
13 Optimize the operation of weigh feeder venting bag filter 6.57 3.00 5
14 Maintain optimum DP across the bag filter 2.19 2.00 11
15 Avoid venting of air in packing plant area blower 0.88 0.50 7
16 Install string switch for lightning in cable room 1.00 0.20 2
14
Energy Saving Projects implemented in FY 2016-17 With No Investment
S. No Energy Saving projectAnnual Savings
(Rs. In Lakh)
Investment Required
( Rs. In Lakhs)
Payback Period
( In Months)
1 Reduce compressed air generating pressure for packingplant compressor
3.2 Nil Immediate
2 Optimize the lighting voltage 2.0 Nil Immediate
3 Optimize capacity of identified motors 0.6 Nil Immediate
4Optimize the loading of distribution transformers
0.22 Nil Immediate
15
Energy Saving Projects implemented in FY 2016-17 With Investment
S. No Energy Saving projectAnnual Savings
(Rs. In Lakh)
Investment Required
( Rs. In Lakhs)
Payback Period
( In Months)
5Rerouting of compressed air line to operate 02packers by 01 compressor
9.2 4.0 5
6 Optimize the operation of Packer 03 Bag Filter 3.99 NIL Immediate
7 Optimize the operation of Packer 04 Bag Filter 4.51 NIL Immediate
8 Avoid compressed air leakage in the plant 10.00 Nil Immediate
9 Increase specific surface area of grinding media in 2nd
chamber of CM-1&230 Nil
10 Optimize the bag filter DP in cement silo-2 topbag filter
1.70 2.00 14
16
Energy Saving Projects implemented in FY 2017-18 With No Investment
S. No Energy Saving projectAnnual Savings
(Rs. In Lakh)
Investment Required
( Rs. In Lakhs)
Payback Period
( In Months)
1 Optimize the suction of bag filter inlet for weigh feederventing bag filters – 201 FN 01
0.76 0 0
2 Optimize the suction of bag filter inlet for weighfeeder venting bag filters – 202 FN 01
0.65 0 0
3 Optimize the operation of Packer 01 & 02 Bag Filters 1.0 0 0
4 Optimize the operation of Packer 03 & 04 Bag Filters 2.0 0 0
5 Optimize the lighting voltage 2.0 0 0
6 Optimize capacity of identified motors 0.6 0 0
17
Energy Saving Projects implemented in FY 2017-18 With Investment
S. No Energy Saving projectAnnual Savings
(Rs. In Lakh)
Investment Required
( Rs. In Lakhs)
Payback Period
( In Months)
1 Replace cooling water pumps with high efficiencyapplications
6.25 5.0 9
2 Improve cooling tower performance 4.0 4.8 15
3 Install VFD for feed building compressor 5.3 9.5 22
4 Avoid compressed air leakage in packing plant 10 2 2.5
5 Avoid unloading of identified compressor by installinglower capacity compressor
3.5 6 20
6 Optimize the operation of wagon tippler bag filter 4.2 0 0
18
Energy Saving Projects implemented in FY 2018-19 With No Investment
S. No Energy Saving projectAnnual Savings
(Rs. In Lakh)
Investment Required
( Rs. In Lakhs)
Payback Period
( In Months)
1 Optimizing the lighting voltage1.0 0 0
2 Optimize capacity of identified motors 0.6 0 0
3 Optimizing the loading of distribution transformers 0.22 0 0
4 Optimize the operation of Packer 1 Bag Filters Under Progress - -
5 Optimize the operation of Packer 2 Bag Filters Under Progress - -
6 Optimize the operation of Packer 3 Bag Filters Under Progress - -
7 Optimize the operation of Packer 4 Bag Filters Under Progress - -
19
Energy Saving Projects implemented in FY 2018-19 With Investment
S. No Energy Saving projectAnnual Savings
(Rs. In Lakh)
Investment Required
( Rs. In Lakhs)
Payback Period
( In Months)
1 Replace identified compressor with energy efficient screwcompressor
Under Progress - -
2 Improve the power factor at Main Incomer Under Progress - -
3 Replace cooling water pumps with high efficiency pump Under progress - -
4 Improve cooling tower performance Under Progress - -
5 Increase specific surface area of grinding media in 2nd
chamber of CM-1& 2Under Progress - -
6 Install latest control systems for mill Under study - -
20
21
61447
118722
020000400006000080000
100000120000140000
16-17 17-18
UN
ITS
GEN
ERA
TED
YEAR
Solar Power Generation
GREEN TOWNSHIP• 102 KWp Solar Power Panel installed in Plant.• Working since October 2016.• Colony Power requirement mainly catered
through Solar Power Generation.
UTILIZATION OF RENEWABLE ENERGY
22
Reduction in Process Water Consumption
• Zero Water Spray for PPC• Reduction in process water consumption
4871.5
4553.2
4320.8
4000
4200
4400
4600
4800
5000
PROCESS WATER CONSUMPTION (KL)
15-16 16-17 17-18
CARBON FOOTPRINT REDUCTION
• Initiative to reduce Carbon Footprint
1. Installation of 102 KWp Solar Power Plant to utilize renewable energy.
2. Reduction of total KWh consumption through various initiatives.
3. Improving Clinker Factor by higher addition of Fly Ash.
4. Installation of 110 kw vacuum pump in place of diesel operated TPS machine to clean clinker dust
23
DETAIL OF INNOVATIVE PROJECTS
24
INNOVATIVE PROJECT NO-1
2 PACKER 8 POINT SYSTEM
25
• OBJECTIVES
1) TO REDUCE IDLE RUN OF PACKING PLANT
2) USE OF ONE COMPRESSOR IN PLACE OF TWO
PROJECT DESCRIPTION:
• IT WAS OBSERVED THAT IDLE HOUR OF PACKING PLANT WAS NEAR ABOUT 38 -40 %.
• WE HAD TO RUN ALL 4 PACKERS AT 8 POINTS TO LOAD TRUCKS. EACH TRUCK PLACEMENT TIME TOOK ATLEAST 8 -10 MIS.
• FOR 4 PACKERS WE HAD TO RUN 2 COMPRESSORS WHICH CONSUMED HUGE POWER
26
TRU
CK
LOA
DIN
G P
OIN
TSCONVEYOR
TRU
CK
LOA
DIN
G YA
RD
BAG DIVERTERS
PREVIOUS 4 PACKER 8 POINT SYSTEM
RUNNING BELT
STOP BELT
8 TO 10 MINS PLACEMENT TIME
1
2
3
4
5
6
7
8
P1 P2 P3 P4
27
P1 P2
TWO PACKER 8 POINT SYSTEM
TRUCK LOADING POINT
TRUCKYARD
PLACEMENT DELAY 1MIN APPROX
1
2
3
4
5
6
7
8
RUNNING BELT
STOP BELT
CONVEYOR
BAG DIVERTERS
28
29
FIXED CLOSED DIVERTER DIVERTER TO BE
OPERATED
• TOTAL RUNNING LOAD FOR ONE PACKER GROUP= 158 KW
TOTAL RUNNING LOAD FOR TWO PACKER GROUP= 158*2= 316 KW
• COMPRESSOR LOAD = 70 KW
• TOTAL LOAD = 316+70 =386 KW
HENCE, SAVING FOR 180 MINS=386 *3=1158 UNITS
RESULTS
UNIT SAVED PER DAY UNIT SAVED PER YEAR TONNAGE 16-17 UNITS PER TON
1158 416880 1695191 0.25
30
INNOVATIVE PROJECT NO-2
INTERLOCK OF CONVEYOR BELTS AND ELEVATOR LOAD WITH BAG FILTER TO REDUCE RPM
31
STORAGE BINMATERIAL FROM SILO
ROTO PACKER
LOAD 48 KW
RPM 1150KW 19.6
AUXILLARY BAG FILTER FAN
STORAGE BIN
LOAD 30 KW
RPM 900KW 9.3
SAVING OF 10 KW
NO MATERIAL FROM SILO
LOW SUCCTION NREQUIRED
32
TRU
CK
LOA
DIN
G P
OIN
TSCONVEYOR
TRU
CK
LOA
DIN
G YA
RD
RUNNING BELT
STOP BELT
2 T0 3 MINS PLACEMENT TIME
4
P1
Air in
DUST GENERATED AT THIS POINT
ONLY
RPM 1150KW 50
RPM 900KW 24
SAVING =26 KW
AIR OUT
BAG FILTER FAN
BELT – BAG FILTER INTERLOCK SYSTEM
33
NO DUST GENERATION
RPM 800KW12
SAVING = 38 KW
BENEFITS
• CONSIDERING 20 RUN- HRS FOR EACH PACKER AND 25 % IDLE RUN HOUR
IDLE HRS DURATION RPM KW SAVING(UNITS)
5ONE BELT OFF 3.5 900 24 91
BOTH BELTS OFF 1.5 800 17 49.5
TOTAL SAVINGS FOR 2 PACKERS 281 UNITS/DAY
BIN EMPTY FREQUENCY 15 TIMES/DAY
TIME TAKES TO FILL IT 5 MINS
TOTAL EMPTY TIME 1.25 HRS
SAVINGS (KW) 10 KW
SAVINGS (UNIT/DAY) 12.5 PER DAY PER PACKER
SAVINGS FOR 2 PACKERS 25 PER DAY FOR 2 PACKER
TOTAL SAVINGS 306 UNITS/DAY
34
GREEN SUPPLY CHAIN
• Office order issued for procurement of materials considering Energy efficiency.
• Procurement of Energy Efficient Motor only, calculating the landed cost considering the energy efficiency.
• Requesting quotation/offers from various suppliers, energy efficiency criteria must be mentioned on the quotation request form.
• Idle running of equipment, wastage of water, air, fuel etc. will impact performance rating of contractor and the unit will impose penalty on observing such incidence.
35
ENCON ORGANISATION CHART
UNIT HEAD
TECHNICAL HEAD
CEMENT MILL PACKING PLANTRAW MATERIAL HANDLING AND WAGON TIPPLER
ENERGY COORDINATOR
AGENDA• MONITORING OF SECTIONWISE SPECIFIC
POWER ON DAILY BASIS.• WHY- WHY ANALYSIS• REVIEW OF ACTION PLAN• TEAM BUILDING• GENERATION OF NEW IDEAS AND
CONCLUSION WITH ACTION PLAN
36
37
INVOLVEMENT OF EMPLOYEES / TEAM WORK
38
ENERGY MONITORING SYSTEM
39
DAILY POWER REPORT
AWARDS AND ACCOLADES
40
GOLDEN BIRD EXCELLENCE AWARD 2018 Towards Excellence in Health & Safety for Worker
NATIONAL CONVENTION ON QUALITY CONCEPTS
41